Collapsible expansion cone

ABSTRACT

An apparatus for radially expanding and plastically deforming an expandable tubular member includes a collapsible expansion cone.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage patent applicationcorresponding to PCT patent application Ser. No. PCT/US02/36157, filedon Nov. 12, 2002, which claimed the benefit of the filing dates of: (1)U.S. provisional patent application Ser. No. 60/338,996, filed on Nov.12, 2001, (2) U.S. provisional patent application Ser. No. 60/339,013,filed on Nov. 12, 2001 (3) U.S. provisional patent application Ser. No.60/363,829, filed on Mar. 13, 2002, and (4) U.S. provisional patentapplication Ser. No. 60/387,961, filed on Jun. 12, 2002, the disclosuresof which are incorporated herein by reference.

The present application is related to the following: (1) U.S. patentapplication Ser. No. 09/454,139, filed on Dec. 3, 1999, (2) U.S. patentapplication Ser. No. 09/510,913, filed on Feb. 23, 2000, (3) U.S. patentapplication Ser. No. 09/502,350, filed on Feb. 10, 2000, (4) U.S. Pat.No. 6,328,113, (5) U.S. patent application Ser. No. 09/523,460, filed onMar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, filed onFeb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, filed onFeb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, filed onJun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, filed onApr. 26, 2000, (10) PCT patent application Ser. No. PCT/US00/18635,filed on Jul. 9, 2000, (11) U.S. provisional patent application Ser. No.60/162,671, filed on Nov. 1, 1999, (12) U.S. provisional patentapplication Ser. No. 60/154,047, filed on Sep. 16, 1999, (13) U.S.provisional patent application Ser. No. 60/159,082, filed on Oct. 12,1999, (14) U.S. provisional patent application Ser. No. 60/159,039,filed on Oct. 12, 1999, (15) U.S. provisional patent application Ser.No. 60/159,033, filed on Oct. 12, 1999, (16) U.S. provisional patentapplication Ser. No. 60/212,359, filed on Jun. 19, 2000, (17) U.S.provisional patent application Ser. No. 60/165,228, filed on Nov. 12,1999, (18) U.S. provisional patent application Ser. No. 60/221,443,filed on Jul. 28, 2000, (19) U.S. provisional patent application Ser.No. 60/221,645, filed on Jul. 28, 2000, (20) U.S. provisional patentapplication Ser. No. 60/233,638, filed on Sep. 18, 2000, (21) U.S.provisional patent application Ser. No. 60/237,334, filed on Oct. 2,2000, (22) U.S. provisional patent application Ser. No. 60/270,007,filed on Feb. 20, 2001, (23) U.S. provisional patent application Ser.No. 60/262,434, filed on Jan. 17, 2001, (24) U.S. provisional patentapplication Ser. No. 60/259,486, filed on Jan. 3, 2001, (25) U.S.provisional patent application Ser. No. 60/303,740, filed on Jul. 6,2001, (26) U.S. provisional patent application Ser. No. 60/313,453,filed on Aug. 20, 2001, (27) U.S. provisional patent application Ser.No. 60/317,985, filed on Sep. 6, 2001, (28) U.S. provisional patentapplication Ser. No. 60/318,021, filed on Sep. 7, 2001, (29) U.S.provisional patent application Ser. No. 60/3318,386, filed on Sep. 10,2001, (30) U.S. provisional patent application Ser. No. 60/326,886,filed on Oct. 3, 2001, (31) U.S. utility patent application Ser. No.09/969,922, filed on Oct. 3, 2001, (32) U.S. provisional patentapplication Ser. No. 60/338,996, filed on Nov. 12, 2001, (33) U.S.provisional patent application Ser. No. 60/339,013, filed on Nov. 12,2001, (34) U.S. utility patent application Ser. No. 10/016,467, filed onDec. 10, 2001, (35) U.S. provisional patent application Ser. No.60/343,674, filed on Dec. 27, 2001, (36) U.S. provisional patentapplication Ser. No. 60/346,309, filed on Jan. 7, 2002, (37) U.S.provisional patent application Ser. No. 60/357,372, filed on Feb. 15,2002, (38) U.S. provisional patent application Ser. No. 60/363,829,filed on Mar. 13, 2002, (39) U.S. provisional patent application Ser.No. 60/372,048, filed on Apr. 12, 2002, (40) U.S. provisional patentapplication Ser. No. 60/372,632, filed on Apr. 15, 2002, (41) U.S.provisional patent application Ser. No. 60/380,147, filed on May 6,2002, (42) U.S. provisional patent application Ser. No. 60/383,917,filed on May 29, 2002, (43) U.S. provisional patent application Ser. No.60/387,486, filed on Jun. 10, 2002, (44) U.S. provisional patentapplication Ser. No. 60/387,961, filed on Jun. 12, 2002, (45) U.S.provisional patent application Ser. No. 60/391,703, filed on Jun. 26,2002, (46) U.S. provisional patent application Ser. No. 60/397,284,filed on Jul. 19, 2002, (47) U.S. provisional patent application Ser.No. 60/398,061, filed on Jul. 24, 2002, (48) U.S. provisional patentapplication Ser. No. 60/399,240, filed on Jul. 29, 2002, (49) U.S.provisional patent application Ser. No. 60/405,610, filed on Aug. 23,2002, (50) U.S. provisional patent application Ser. No. 60/405,394,filed on Aug. 23, 2002, (51) U.S. provisional patent application Ser.No. 60/407,442, filed on Aug. 30, 2002, (52) U.S. provisional patentapplication Ser. No. 60/412,542, filed on Sep. 20, 2002, (53) U.S.provisional patent application Ser. No. 60/412,177, filed on Sep. 20,2002, (54) U.S. provisional patent application Ser. No. 60/412,653,filed on Sep. 20, 2002, (55) U.S. provisional patent application Ser.No. 60/412,544, filed on Sep. 20, 2002, (56) U.S. provisional patentapplication Ser. No. 60/412,187, filed on Sep. 20, 2002, (57) U.S.provisional patent application Ser. No. 60/412,187, filed on Sep. 20,2002, (58) U.S. provisional patent application Ser. No. 60/412,487,filed on Sep. 20, 2002, (59) U.S. provisional patent application Ser.No. 60/412,488, filed on Sep. 20, 2002, and (60) U.S. provisional patentapplication Ser. No. 60/412,371, filed on Sep. 20, 2002, (61) PCT PatentApplication No. PCT/US02/36157, filed on Nov. 11, 2002 and (62) PCTPatent Application No. PCT/US02/36267, filed on Nov. 11, 2002, thedisclosures of which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

This invention relates generally to oil and gas exploration, and inparticular to forming and repairing wellbore casings to facilitate oiland gas exploration.

During oil exploration, a wellbore typically traverses a number of zoneswithin a subterranean formation. Wellbore casings are then formed in thewellbore by radially expanding and plastically deforming tubular membersthat are coupled to one another by threaded connections. Existingmethods for radially expanding and plastically deforming tubular memberscoupled to one another by threaded connections are not always reliableor produce satisfactory results. In particular, the threaded connectionscan be damaged during the radial expansion process.

The present invention is directed to overcoming one or more of thelimitations of the existing processes for radially expanding andplastically deforming tubular members coupled to one another by threadedconnections.

SUMMARY OF THE INVENTION

According to one aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes an upper tubular support memberdefining a first passage, one or more cup seals coupled to the exteriorsurface of the upper tubular support member for sealing an interfacebetween the upper tubular support member and the expandable tubularmember, an upper cam assembly coupled to the upper tubular supportmember comprising: a tubular base coupled to the upper tubular supportmember, and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface, a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to thetubular support member, a lower tubular support member defining a secondpassage fluidicly coupled to the first passage releasably coupled to theupper tubular support member, and a lower cam assembly coupled to thelower tubular support member comprising: a tubular base coupled to thelower tubular support member, and a plurality of cam arms extending fromthe tubular base in an upward longitudinal direction, each cam armdefining an inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments, wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly, a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly, wherein the lower expansion conesegments interleave and overlap the upper expansion cone segments, andwherein the upper and lower expansion cone segments together define anarcuate spherical external surface for plastically deforming andradially expanding the expandable tubular member.

According to another aspect of the present invention, a collapsibleexpansion cone assembly is provided that includes an upper tubularsupport member comprising an internal flange, an upper cam assemblycoupled to the upper tubular support member comprising: a tubular basecoupled to the upper support member, and a plurality of cam armsextending from the tubular base in a downward longitudinal direction,each cam arm defining an inclined surface, a plurality of upperexpansion cone segments interleaved with the cam arms of the upper camassembly and pivotally coupled to the internal flange of the uppertubular support member, a lower tubular support member comprising aninternal flange, one or more frangible couplings for releasably couplingthe upper and lower tubular support members, a lower cam assemblycoupled to the lower tubular support member comprising: a tubular basecoupled to the lower tubular support member, and a plurality of cam armsextending from the tubular base in an upward longitudinal direction,each cam arm defining an inclined surface that mates with the inclinedsurface of a corresponding one of the upper expansion cone segments,wherein the cams arms of the upper cam assembly are interleaved with andoverlap the cam arms of the lower cam assembly, and a plurality of lowerexpansion cone segments interleaved with cam arms of the lower camassembly, each lower expansion cone segment pivotally coupled to theinternal flange of the lower tubular support member and mating with theinclined surface of a corresponding one of the cam arms of the upper camassembly, wherein the lower expansion cone segments interleave andoverlap the upper expansion cone segments, and wherein the upper andlower expansion cone segments together define an arcuate sphericalexternal surface for plastically deforming and radially expanding theexpandable tubular member.

According to another aspect of the present invention, an apparatus forradially expanding and plastically deforming an expandable tubularmember is provided that includes a tubular support member, a collapsibleexpansion cone coupled to the tubular support member, an expandabletubular member coupled to the collapsible expansion cone, means fordisplacing the collapsible expansion cone relative to the expandabletubular member, and means for collapsing the expansion cone.

According to another aspect of the present invention, a collapsibleexpansion cone is provided that includes an upper cam assemblycomprising: a tubular base, and a plurality of cam arms extending fromthe tubular base in a downward longitudinal direction, each cam armdefining an inclined surface, a plurality of upper expansion conesegments interleaved with the cam arms of the upper cam assembly, alower cam assembly comprising: a tubular base, and a plurality of camarms extending from the tubular base in an upward longitudinaldirection, each cam arm defining an inclined surface that mates with theinclined surface of a corresponding one of the upper expansion conesegments, wherein the cams arms of the upper cam assembly areinterleaved with and overlap the cam arms of the lower cam assembly, aplurality of lower expansion cone segments interleaved with cam arms ofthe lower cam assembly, each lower expansion cone segment mating withthe inclined surface of a corresponding one of the cam arms of the uppercam assembly, means for moving the upper cam assembly away from thelower expansion cone segments, and means for moving the lower camassembly away from the upper expansion cone segments.

According to another aspect of the invention, an apparatus for radiallyexpanding and plastically deforming an expandable tubular member isprovided that includes a tubular support member, a collapsible expansioncone coupled to the tubular support member, an expandable tubular membercoupled to the collapsible expansion cone, means for displacing thecollapsible expansion cone relative to the expandable tubular member,and means for collapsing the expansion cone.

According to another aspect of the invention, a collapsible expansioncone is provided that includes an upper cam assembly comprising: atubular base, and a plurality of cam arms extending from the tubularbase in a downward longitudinal direction, each cam arm defining aninclined surface, a plurality of upper expansion cone segmentsinterleaved with the cam arms of the upper cam assembly, a lower camassembly comprising: a tubular base, and a plurality of cam armsextending from the tubular base in an upward longitudinal direction,each cam arm defining an inclined surface that mates with the inclinedsurface of a corresponding one of the upper expansion cone segments,wherein the cams arms of the upper cam assembly are interleaved with andoverlap the cam arms of the lower cam assembly, a plurality of lowerexpansion cone segments interleaved with cam arms of the lower camassembly, each lower expansion cone segment mating with the inclinedsurface of a corresponding one of the cam arms of the upper camassembly, means for moving the upper cam assembly away from the lowerexpansion cone segments, and means for moving the lower cam assemblyaway from the upper expansion cone segments.

According to another aspect of the invention, a method of radiallyexpanding and plastically deforming an expandable tubular member isprovided that includes supporting the expandable tubular member using atubular support member and a collapsible expansion cone, injecting afluidic material into the tubular support member, sensing the operatingpressure of the injected fluidic material within a first interiorportion of the tubular support member, displacing the collapsibleexpansion cone relative to the expandable tubular member when the sensedoperating pressure of the injected fluidic material exceeds apredetermined level within the first interior portion of the tubularsupport member, sensing the operating pressure of the injected fluidicmaterial within a second interior portion of the tubular support member,and collapsing the collapsible expansion cone when the sensed operatingpressure of the injected fluidic material exceeds a predetermined levelwithin the second interior portion of the tubular support member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a fragmentary cross-sectional illustration of the placementof a portion of an exemplary embodiment of an apparatus for radiallyexpanding and plastically deforming a tubular member that includes acollapsible expansion cone within a preexisting structure.

FIG. 1 b is a fragmentary cross-sectional illustration of anotherportion of the apparatus of FIG. 1 a.

FIGS. 2 a and 2 b are fragmentary cross-sectional illustration of aportion of the apparatus of FIGS. 1 a and 1 b.

FIG. 3 is a fragmentary cross-sectional illustration of a portion of theapparatus of FIGS. 1 a and 1 b.

FIG. 3 a is a fragmentary cross-sectional illustration of a portion ofthe apparatus of FIG. 3.

FIG. 3 b is a fragmentary cross-sectional illustration of a portion ofthe apparatus of FIG. 3.

FIG. 4 is a fragmentary cross-sectional illustration of a portion of theapparatus of FIGS. 1 a and 1 b.

FIG. 4 a is a fragmentary cross-sectional illustration of a portion ofthe apparatus of FIG. 4.

FIG. 5 is a fragmentary cross-sectional illustration of a portion of theapparatus of FIGS. 1 a and 1 b.

FIG. 6 is a fragmentary cross-sectional illustration of a portion of theapparatus of FIGS. 1 a and 1 b.

FIGS. 7 a-7 e are fragmentary cross-sectional and perspectiveillustrations of the upper cam assembly of the apparatus of FIGS. 1 aand 1 b.

FIG. 7 f is a fragmentary cross-sectional illustration of the lower camassembly of the apparatus of FIGS. 1 a and 1 b.

FIGS. 8 a-8 d are fragmentary cross-sectional and perspectiveillustrations of one of the upper cone segments of the apparatus ofFIGS. 1 a and 1 b.

FIG. 8 e is a fragmentary cross-sectional illustration of one of thelower cone segments of the apparatus of FIGS. 1 a and 1 b.

FIG. 9 is a side view of a portion of the apparatus of FIGS. 1 a and 1b.

FIG. 10 a is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 1 a and 1 b during the radial expansion of theexpandable tubular member.

FIG. 10 b is a fragmentary cross sectional illustration of anotherportion of the apparatus of FIG. 10 a.

FIG. 11 a. is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 10 a and 10 b during the adjustment of theexpansion cone to a collapsed position.

FIG. 11 b is a fragmentary cross sectional illustration of anotherportion of the apparatus of FIG. 11 a.

FIG. 12 is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 11 a and 11 b.

FIG. 13 is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 11 a and 11 b.

FIG. 14 is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 11 a and 11 b with the expansion cone in a halfcollapsed position.

FIG. 15 is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 11 a and 11 b with the expansion cone in a fullycollapsed position.

FIG. 16 is a side view of a portion of the apparatus of FIGS. 10 a and10 b.

FIG. 17 a. is a fragmentary cross sectional illustration of a portion ofthe apparatus of FIGS. 11 a and 11 b after the removal of the apparatusfrom interior of the expandable tubular member.

FIG. 17 b is a fragmentary cross sectional illustration of anotherportion of the apparatus of FIG. 17 a.

DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring to FIGS. 1 a, 1 b, 2 a, 2 b, 3, 3 a, 4, 4 a, 5, 6, 7 a, 7 b, 7c, 7 d, 7 e, 7 f, 8 a, 8 b, 8 c, 8 d, 8 e, and 9, an exemplaryembodiment of an apparatus 10 for radially expanding and plasticallydeforming a tubular member includes a tubular support member 12 thatdefines a passage 12 a. An end of the tubular support member 12 iscoupled to an end of a safety collar 14 that defines a passage 14 a, arecess 14 b at one end for receiving the end of the tubular supportmember, and recesses 14 c and 14 d at another end.

A torque plate 16 is received within and is coupled to the recess 14 cof the safety collar 14 that defines a passage 16 a and a plurality ofmeshing teeth 16 b at one end. An end of an upper mandrel collar 18 isreceived with and is coupled to the recess 14 d of the safety collar 14proximate and end of the torque plate 16 that defines a passage 18 a.Torque pins 20 a and 20 b further couple the end of the upper mandrelcollar 18 to the end of the safety collar 14.

An end of an upper mandrel 22 is received within and is coupled to theupper mandrel collar 18 that defines a passage 22 a, a plurality ofmeshing teeth 22 b that mate with and transmit torque to and from themeshing teeth 16 b of the torque plate 16, and an external flange 22 cat another end.

An upper packer cup 24 mates with, receives and is coupled to the uppermandrel 22 proximate the end of the upper mandrel collar 18. In anexemplary embodiment, the upper packer cup 24 is a Guiberson™ packercup. An upper spacer sleeve 26 mates with, receives, and is coupled tothe upper mandrel 22 proximate an end of the upper packer cup 24. Alower packer cup 28 mates with, receives and is coupled to the uppermandrel 22 proximate an end of the upper spacer sleeve 26. In anexemplary embodiment, the lower packer cup 28 is a Guiberson™ packercup. A lower spacer sleeve 30 mates with, receives, and is coupled tothe upper mandrel 22 proximate an end of the lower packer cup 28 and theexternal flange 22 c of the upper mandrel. A retaining sleeve 32 mateswith, receives, and is coupled to an end of the lower spacer sleeveproximate the external flange 22 c of the upper mandrel 22.

An end of a lower mandrel 34 defines a recess 34 a that mates with,receives, and is coupled to the external flange 22 c of the uppermandrel 22, a recess 34 b that mates with, receives, and is coupled tothe end of the upper mandrel, a passage 34 c, and an external flange 34d including circumferentially spaced apart meshing teeth 34 da on an endface of the external flange. Torque pins 36 a and 36 b further couplethe recess 34 a of the end of the lower mandrel 34 to the externalflange 22 c of the upper mandrel 22. During operation, the torque pins36 a and 36 b transmit torque loads between the recess 34 a of the endof the lower mandrel 34 and the external flange 22 c of the uppermandrel 22.

An upper cam assembly 38 includes a tubular base 38 a for receiving andmating with the lower mandrel 34 that includes an external flange 38 aa,a plurality of circumferentially spaced apart meshing teeth 38 b thatextend from one end of the tubular base in the longitudinal and radialdirections for engaging the meshing teeth 34 da of the end face of theexternal flange 34 d of the lower mandrel, and a plurality ofcircumferentially spaced apart cam arms 38 c that extend from the otherend of the tubular base in the opposite longitudinal direction and matewith and receive the lower mandrel. During operation, the meshing teeth34 da of the end face of the external flange 34 d of the lower mandrel34 transmit torque loads to the meshing teeth 38 b of the upper camassembly 38. Each of the cam arms 38 c include an inner portion 38 caextending from the tubular base 38 a that has arcuate cylindrical innerand outer surfaces, 38 caa and 38 cab, a tapered intermediate portion 38cb extending from the inner portion that has an arcuate cylindricalinner surface 38 cba and an arcuate conical outer surface 38 cbb, and anouter portion 38 cc extending from the intermediate portion that hasarcuate cylindrical inner and outer surfaces, 38 cca and 38 ccb. In anexemplary embodiment, the radius of curvatures of the arcuate outercylindrical surfaces 38 cab are greater than the radius of curvatures ofthe arcuate outer cylindrical surfaces 38 ccb. In an exemplaryembodiment, the radius of curvatures of the arcuate inner cylindricalsurfaces, 38 caa, 38 cba, and 38 cca are equal.

A lower cam assembly 40 includes a tubular base 40 a for receiving andmating with the lower mandrel 34 that includes an external flange 40 aa,a plurality of circumferentially spaced apart meshing teeth 40 b thatextend from one end of the tubular base in the longitudinal and radialdirections, and a plurality of circumferentially spaced apart cam arms40 c that extend from the other end of the tubular base in the oppositelongitudinal direction and mate with and receive the lower mandrel. Eachof the cam arms 40 c include an inner portion 40 ca extending from thetubular base 40 a that has arcuate cylindrical inner and outer surfaces,40 caa and 40 cab, a tapered intermediate portion 40 cb extending fromthe inner portion 40 ca that has an arcuate cylindrical inner surface 40cba and an arcuate conical outer surface 40 cbb, and an outer portion 40cc extending from the intermediate portion that has arcuate cylindricalinner and outer surfaces, 40 cca and 40 ccb. In an exemplary embodiment,the radius of curvatures of the arcuate outer cylindrical surfaces 40cab are greater than the radius of curvatures the arcuate outercylindrical surfaces 40 ccb. In an exemplary embodiment, the radius ofcurvatures of the arcuate inner cylindrical surfaces, 40 caa, 40 cba,and 40 cca are equal. In an exemplary embodiment, the upper and lowercam assemblies, 38 and 40, are substantially identical. In an exemplaryembodiment, the cam arms 38 c of the upper cam assembly 38 interleavethe cam arms 40 c of the lower cam assembly 40. Furthermore, in anexemplary embodiment, the cam arms 38 c of the upper cam assembly alsooverlap with the cam arms 40 c of the lower cam assembly 40 in thelongitudinal direction thereby permitting torque loads to be transmittedbetween the upper and lower cam assemblies.

An end of an upper retaining sleeve 42 receives and is threadablycoupled to the external flange 34 d of the lower mandrel 34 that definesa passage 42 a for receiving and mating with the outer circumferentialsurfaces of the external flange 38 aa and the meshing teeth 38 b of theupper cam assembly 38, and an inner annular recess 42 b, and includes aninternal flange 42 c for retaining the external flange 38 aa of theupper cam assembly, and an internal flange 42 d at one end of the upperretaining sleeve that includes a rounded interior end face. An o-ringseal 44 is received within the annular recess 42 b for sealing theinterface between the upper retaining sleeve 42 and the external flange34 d of the lower mandrel 34. A disc shaped shim 43 is positioned withinthe upper retaining sleeve 42 between the opposing end faces of theinternal flange 42 c of the retaining sleeve and the meshing teeth 38 bof the upper cam assembly 38.

A plurality of upper expansion cone segments 44 are interleaved amongthe cam arms 38 c of the upper cam assembly 38. Each of the upperexpansion cone segments 44 include inner portions 44 a having arcuatecylindrical inner surfaces, 44 aaa and 44 aab, and an arcuatecylindrical outer surface 44 ab, intermediate portions 44 b extendingfrom the interior portions that have an arcuate conical inner surface 44ba and arcuate cylindrical and spherical outer surfaces, 44 bba and 44bbb, and outer portions 44 c having arcuate cylindrical inner and outersurfaces, 44 ca and 44 cb. In an exemplary embodiment, the outersurfaces 44 ab of the inner portions 44 a of the upper expansion conesegments define hinge grooves 44 aba that receive and are pivotallymounted upon the internal flange 42 d of the upper retaining sleeve 42.

The arcuate inner cylindrical surfaces 44 aaa mate with and receive thelower mandrel 34, the arcuate inner cylindrical surfaces 44 aab matewith and receive the arcuate cylindrical outer surfaces 40 ccb of theouter portions 40 cc of the corresponding cam arms 40 c of the lower camassembly 40, and the arcuate inner conical surfaces 44 ba mate with andreceive the arcuate conical outer surfaces 40 cbb of the intermediateportions 40 cb of the corresponding cam arms of the lower cam assembly.

In an exemplary embodiment, the radius of curvature of the arcuatecylindrical inner surface 44 aaa is less than the radius of curvature ofthe arcuate cylindrical inner surface 44 aab. In an exemplaryembodiment, the radius of curvature of the arcuate cylindrical innersurface 44 ca is greater than the radius of curvature of the arcuatecylindrical surface 44 aab. In an exemplary embodiment, the arcuatecylindrical inner surfaces, 44 aaa and 44 aab, are parallel. In anexemplary embodiment, the arcuate cylindrical outer surface 44 ab isinclined relative to the arcuate cylindrical inner surface 44 aaa. In anexemplary embodiment, the arcuate cylindrical outer surface 44 bba isparallel to the arcuate cylindrical inner surfaces, 44 aaa and 44 aab.In an exemplary embodiment, the arcuate cylindrical outer surface 44 cbis inclined relative to the arcuate cylindrical inner surface 44 ca.

A plurality of lower expansion cone segments 46 are interleaved among,and overlap, the upper expansion cone segments 44 and the cam arms 38 cof the lower cam assembly 38. In this manner, torque loads may betransmitted between the upper and lower expansion cone segments, 44 and46. Each of the lower expansion cone segments 46 include inner portions46 a having arcuate cylindrical inner surfaces, 46 aaa and 46 aab, andan arcuate cylindrical outer surface 46 ab, intermediate portions 46 bextending from the interior portions that have an arcuate conical innersurface 46 ba and arcuate cylindrical and spherical outer surfaces, 46bba and 46 bbb, and outer portions 46 c having arcuate cylindrical innerand outer surfaces, 46 ca and 46 cb. In an exemplary embodiment, theouter surfaces 46 ab of the inner portions 46 a of the upper expansioncone segments 46 define hinge grooves 46 aba.

The arcuate inner cylindrical surfaces 46 aaa mate with and receive thelower mandrel 34, the arcuate inner cylindrical surfaces 46 aab matewith and receive the arcuate cylindrical outer surfaces 38 ccb of theouter portions 38 cc of the corresponding cam arms 38 c of the upper camassembly 38, and the arcuate inner conical surfaces 46 ba mate with andreceive the arcuate conical outer surfaces 38 cbb of the intermediateportions 38 cb of the corresponding cam arms of the lower cam assembly.

In an exemplary embodiment, the radius of curvature of the arcuatecylindrical inner surface 46 aaa is less than the radius of curvature ofthe arcuate cylindrical inner surface 46 aab. In an exemplaryembodiment, the radius of curvature of the arcuate cylindrical innersurface 46 ca is greater than the radius of curvature of the arcuatecylindrical surface 46 aab. In an exemplary embodiment, the arcuatecylindrical inner surfaces, 46 aaa and 46 aab, are parallel. In anexemplary embodiment, the arcuate cylindrical outer surface 46 ab isinclined relative to the arcuate cylindrical inner surface 46 aaa. In anexemplary embodiment, the arcuate cylindrical outer surface 46 bba isparallel to the arcuate cylindrical inner surfaces, 46 aaa and 46 aab.In an exemplary embodiment, the arcuate cylindrical outer surface 46 cbis inclined relative to the arcuate cylindrical inner surface 46 ca.

In an exemplary embodiment, the geometries of the upper and lowerexpansion cone segments 44 and 46 are substantially identical. In anexemplary embodiment, the upper expansion cone segments 44 are taperedin the longitudinal direction from the ends of the intermediate portions44 b to the ends of the outer portions 44 c, and the lower expansioncone segments 46 are tapered in the longitudinal direction from the endsof the intermediate portions 46 b to the ends of the outer portions 46c. In an exemplary embodiment, when the upper and lower expansionsegments, 44 and 46, are positioned in a fully expanded position, thearcuate cylindrical outer surfaces, 44 bba and 46 cb, of the upper andlower expansion cone segments define a contiguous cylindrical surface,the arcuate spherical outer surfaces, 44 bbb and 46 bbb, of the upperand lower expansion cone segments define an contiguous arcuate sphericalsurface, and the arcuate cylindrical outer surfaces, 44 cb and 46 bba,of the upper and lower expansion cone segments define a contiguouscylindrical surface.

An end of a lower retaining sleeve 48 defines a passage 48 a forreceiving and mating with the outer circumferential surfaces of theexternal flange 40 aa and the meshing teeth 40 b of the lower camassembly 40, and an inner annular recess 48 b, and includes an internalflange 48 c for retaining the external flange of the lower cam assembly,and an internal flange 48 d at one end of the lower retaining sleevethat includes a rounded interior end face for mating with the hingegrooves 46 aba of the lower expansion cone segments 46 thereby pivotallycoupling the lower expansion cone segments to the lower retainingsleeve. An o-ring seal 50 is received within the annular recess 48 b. Adisc shaped shim 49 is positioned within the lower retaining sleeve 48between the opposing end faces of the internal flange 48 c of theretaining sleeve and the external flange 40 aa of the lower cam assembly40.

In an exemplary embodiment, the arcuate cylindrical outer surfaces 44bba of the upper expansion cone segments 44 and the arcuate cylindricalouter surfaces 46 cb of the lower expansion cone segments 46 are alignedwith the outer surface of the upper retaining sleeve 42. In an exemplaryembodiment, the arcuate cylindrical outer surfaces 44 cb of the upperexpansion cone segments 44 and the arcuate cylindrical outer surfaces 46bba of the lower expansion cone segments are aligned with the outersurface of the lower retaining sleeve 48.

An end of a float shoe adaptor 50 that includes a plurality ofcircumferentially spaced apart meshing teeth 50 a for engaging themeshing teeth 40 b of the lower cam assembly 40 is received within andthreadably coupled to an end of the lower retaining sleeve 48 thatdefines a passage 50 b at one end for receiving an end of the lowermandrel 34, a passage 50 c having a reduced inside diameter at anotherend, a plurality of radial passages 50 d at the other end, and includesan internal flange 50 e, and a torsional coupling 50 f at the other endthat includes a plurality of torsional coupling members 50 fa. Duringoperation, the meshing teeth 40 b of the lower cam assembly 40 transmittoque loads to and from the meshing teeth 50 a of the float shoeadaptor.

An end of a retaining sleeve 52 abuts the end face of the tubular base40 a of the lower cam assembly 40 and is received within and mates withthe passage 50 b of the float shoe adaptor 50 that defines a passage 52a for receiving an end of the lower mandrel 34, a throat passage 52 bincluding a ball valve seat 52 c, and includes a flange 52 d, andanother end of the retaining sleeve, having a reduced outside diameter,is received within and mates with the passage 50 c of the float shoeadaptor 50.

A stop nut 54 receives and is threadably coupled to the end of the lowermandrel 34 within the passage 52 a of the retaining sleeve 52, and shearpins 56 releasably couple the stop nut 54 to the retaining sleeve 52.Locking dogs 58 are positioned within an end of the retaining sleeve 52that receive and are releasably coupled to the lower mandrel 34, and adisc shaped adjustment shim 60 receives the lower mandrel 34 and ispositioned within an end of the retaining sleeve 52 between the opposingends of the tubular base 40 a of the upper cam assembly 40 and thelocking dogs 58. Burst discs 62 are releasably coupled to and positionedwithin the radial passages 50 d of the float shoe adaptor 50.

An end of a float shoe 64 mates with and is releasably coupled to thetorsional coupling members 50 fa of the torsional coupling 50 f of thefloat shoe adaptor 50 that defines a passage 64 a and a valveablepassage 64 b. In this manner torsional loads may be transmitted betweenthe float shoe adaptor 50 and the float shoe 64. An end of an expandabletubular member 66 that surrounds the tubular support member 12, thesafety collar 14, the upper mandrel collar 18, the upper packer cup 24,the lower packer cup 28, the lower mandrel 34, the upper expansion conesegments 44, the lower expansion cone segments 46, and the float shoeadaptor 50, is coupled to and receives an end of the float shoe 64 andis movably coupled to and supported by the arcuate spherical externalsurfaces, 44 bbb and 46 bbb, of the upper and lower expansion conesegments, 44 and 46.

During operation, as illustrated in FIGS. 1 a and 1 b, the apparatus 10is at least partially positioned within a preexisting structure such as,for example, a borehole 100 that traverses a subterranean formation thatmay include a preexisting wellbore casing 102. The borehole 100 may beoriented in any position, for example, from vertical to horizontal. Afluidic material 104 is then injected into the apparatus 10 through thepassages 12 a, 14 a, 22 a, 34 c, 50 c, 64 a, and 64 b into the annulusbetween the expandable tubular member 66 and the borehole 100. In anexemplary embodiment, the fluidic material 104 is a hardenable fluidicsealing material. In this manner, an annular sealing layer may be formedwithin the annulus between the expandable tubular member 66 and theborehole 100.

As illustrated in FIGS. 10 a and 10 b, a ball 106 is then be positionedwithin and blocking the valveable passage 64 b of the float shoe 64 byinjecting a fluidic material 108 into the apparatus 10 through thepassages 12 a, 14 a, 22 a, 34 c, and 50 c. As a result, the increasedoperating pressure within the passage 50 c bursts open the burst discs62 positioned within the radial passages 50 d of the float shoe adaptor50. The continued injection of the fluidic material 108 therebypressurizes the interior of the expandable tubular member 66 below thelower packer cup 28 thereby displacing the upper and lower expansioncone segments, 44 and 46, upwardly relative to the float shoe 64 and theexpandable tubular member 66. As a result, the expandable tubular member66 is plastically deformed and radially expanded. Thus, the burst discs62 sense the operating pressure of the injected fluidic material 108within the passage 50 c and thereby control the initiation of the radialexpansion and plastic deformation of the expandable tubular member 66.

In an exemplary embodiment, any leakage of the pressurized fluidicmaterial 108 past the lower packer cup 28 is captured and sealed againstfurther leakage by the upper packer cup 24. In this manner, the lowerpacker cup 28 provides the primary fluidic seal against the interiorsurface of the expandable tubular member 66, and the upper packer cup 24provides a secondary, back-up, fluidic seal against the interior surfaceof the expandable tubular member. Furthermore, because the lower packercup 28 and/or the upper packer cup 24 provide a fluid tight seal againstthe interior surface of the expandable tubular member 66, the upper andlower expansion cone segments, 44 and 46, are pulled upwardly throughthe expandable tubular member by the axial forces created by the packercups.

In an exemplary embodiment, during the radial expansion process, theinterface between the arcuate spherical external surfaces, 44 bbb and 46bbb, of the upper and lower expansion cone segments, 44 and 46, and theinterior surface of the expandable tubular member 66 is not fluid tight.As a result, the fluidic material 108 may provide lubrication to theentire extent of the interface between the cylindrical externalsurfaces, 44 bba and 46 cb, and the arcuate spherical external surfaces,44 bbb and 46 bbb, of the upper and lower expansion cone segments, 44and 46, and the interior surface of the expandable tubular member 66.Moreover, experimental test results have indicated the unexpected resultthat the required operating pressure of the fluidic material 108 forradial expansion of the expandable tubular member 66 is less when theinterface between the cylindrical external surfaces, 44 bba and 46 cb,and the arcuate spherical external surfaces, 44 bbb and 46 bbb, of theupper and lower expansion cone segments, 44 and 46, and the interiorsurface of the expandable tubular member 66 is not fluid tight.Furthermore, experimental test results have also demonstrated that thearcuate spherical external surface provided by the arcuate sphericalexternal surfaces, 44 bbb and 46 bbb, of the upper and lower expansioncone segments, 44 and 46, provides radial expansion and plasticdeformation of the expandable tubular member 66 using lower operatingpressures versus an expansion cone having a conical outer surface.

In an exemplary embodiment, as illustrated in FIGS. 11 a, 11 b, 12, 13,14, 15, and 16, the upper and lower expansion cone segments, 44 and 46,may then be adjusted to a collapsed position by placing a ball 110within the ball valve seat 52 c of the throat passage 52 b of theretaining sleeve 52. The continued injection of the fluidic material108, after the placement of the ball 110 within the ball valve seat 52c, creates a differential pressure across the ball 110 thereby applyinga downward longitudinal force onto the retaining sleeve 52 therebyshearing the shear pins 56. As a result, the retaining sleeve 52 isdisplaced in the downward longitudinal direction relative to the floatshoe adaptor 50 thereby permitting the locking dogs 58 to be displacedoutwardly in the radial direction. The outward radial displacement ofthe locking dogs 58 disengages the locking dogs from engagement with thelower mandrel 34. Thus, the shear pins 56 sense the operating pressureof the injected fluidic material 108 within the throat passage 52 b andthereby controlling the initiation of the collapsing of the upper andlower expansion cone segments, 44 and 46.

The continued injection of the fluidic material 108 continues todisplace the retaining sleeve 52 in the downward longitudinal directionrelative to the float shoe adaptor 50 until the external flange 52 d ofthe retaining sleeve 52 impacts, and applies a downward longitudinalforce to, the internal flange 50 e of the float shoe adaptor. As aresult, the float shoe adaptor 50 is then also displaced in the downwardlongitudinal direction relative to the lower mandrel 34. The downwardlongitudinal displacement of the float shoe adaptor 50 relative to thelower mandrel 34 causes the lower cam assembly 40, the lower expansioncone segments 46, and the lower retaining sleeve 48, which are rigidlyattached to the float shoe adaptor, to also be displaced downwardly inthe longitudinal direction relative to the lower mandrel 34, the uppercam assembly 38, and the upper expansion cone segments 44.

The downward longitudinal displacement of the lower cam assembly 40relative to the upper expansion cone segments 44 causes the upperexpansion cone segments to slide off of the conical external surfaces 40cbb of the lower cam assembly and thereby pivot inwardly in the radialdirection about the internal flange 42 d of the upper retaining sleeve42. The downward longitudinal displacement of the lower expansion conesegments 46 relative to the upper cam assembly 38 causes the lowerexpansion cone segments 46 to slide off of the external conical surfaces38 cbb of the upper cam assembly and thereby pivot inwardly in theradial direction about the internal flange 48 d of the lower retainingsleeve. As a result of the inward radial movement of the upper and lowerexpansion cone segments, 44 and 46, the arcuate external sphericalsurfaces, 44 bbb and 46 bbb, of the upper and lower expansion conesegments, 44 and 46, no longer provide a substantially contiguous outerarcuate spherical surface.

The downward longitudinal movement of the retaining sleeve 42 and floatshoe adaptor 50 relative to the lower mandrel 34 is stopped when thestop nut 54 impacts the locking dogs 58. At this point, as illustratedin FIGS. 17 a and 17 b, the apparatus 10 may then be removed from theinterior of the expandable tubular member 66.

Thus, the apparatus 10 may be removed from the expandable tubular member66 prior to the complete radial expansion and plastic deformation of theexpandable tubular member by controllably collapsing the upper and lowerexpansion cone segments, 44 and 46. As a result, the apparatus 10provides the following benefits: (1) the apparatus is removable whenexpansion problems are encountered; (2) lower expansion forces arerequired because the portion of the expandable tubular member 66 betweenthe packer cups, 24 and 28, and the expansion cone segments is exposedto the expansion fluid pressure; and (3) the expansion cone segments canbe run down through the expandable tubular member, prior to radialexpansion, and then the expansion cone segments can be expanded.

In several alternative embodiments, resilient members such as, forexample, spring elements are coupled to the upper and lower expansioncone segments, 44 and 46, for resiliently biasing the expansion conesegments towards the expanded or collapsed position.

In several alternative embodiments, the placement of the upper and lowerexpansion cone segments, 44 and 46, in an expanded or collapsed positionis reversible as disclosed in PCT patent application serial no.PCT/US02/36267, filed on Nov. 12, 2002, the disclosure of which isincorporated herein by reference.

In several alternative embodiments, a small gap is provided between theupper and lower expansion cone segments, 44 and 46, when positioned inthe expanded condition that varies from about 0.005 to 0.030 inches.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has been described that includes an uppertubular support member defining a first passage, one or more cup sealscoupled to the exterior surface of the upper tubular support member forsealing an interface between the upper tubular support member and theexpandable tubular member, an upper cam assembly coupled to the uppertubular support member comprising: a tubular base coupled to the uppertubular support member, and a plurality of cam arms extending from thetubular base in a downward longitudinal direction, each cam arm definingan inclined surface, a plurality of upper expansion cone segmentsinterleaved with the cam arms of the upper cam assembly and pivotallycoupled to the tubular support member, a lower tubular support memberdefining a second passage fluidicly coupled to the first passagereleasably coupled to the upper tubular support member, a lower camassembly coupled to the lower tubular support member comprising: atubular base coupled to the lower tubular support member, and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each cam arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion cone segments, wherein the cams arms of the upper cam assemblyare interleaved with and overlap the cam arms of the lower cam assembly,and a plurality of lower expansion cone segments interleaved with camarms of the lower cam assembly, each lower expansion cone segmentpivotally coupled to the lower tubular support member and mating withthe inclined surface of a corresponding one of the cam arms of the uppercam assembly, wherein the lower expansion cone segments interleave andoverlap the upper expansion cone segments, and wherein the upper andlower expansion cone segments together define an arcuate sphericalexternal surface for plastically deforming and radially expanding theexpandable tubular member. In an exemplary embodiment, the upper tubularsupport member includes: a safety collar, a torque plate coupled to thesafety collar including a plurality of circumferentially spaced apartmeshing teeth at an end, an upper mandrel including a plurality ofcircumferentially spaced apart meshing teeth at one end for engaging themeshing teeth of the torque plate and an external flange at another end,and a lower mandrel coupled to the external flange of the upper mandrelincluding an external flange including a plurality of circumferentiallyspaced apart meshing teeth. In an exemplary embodiment, the tubular baseof the upper cam assembly includes a plurality of circumferentiallyspaced apart meshing teeth for engaging the meshing teeth of theexternal flange of the lower mandrel. In an exemplary embodiment, theapparatus further includes a stop nut coupled to an end of the lowermandrel for limiting the movement of the lower tubular member relativeto the lower mandrel. In an exemplary embodiment, the apparatus furtherincludes locking dogs coupled to the lower mandrel. In an exemplaryembodiment, the lower tubular support member includes: a float shoeadapter including a plurality of circumferentially spaced apart meshingteeth at one end, an internal flange, and a torsional coupling atanother end, a lower retaining sleeve coupled to an end of the floatshoe adapter including an internal flange for pivotally engaging thelower expansion cone segments, and a retaining sleeve received withinthe float shoe adapter releasably coupled to the upper tubular supportmember. In an exemplary embodiment, an end of the retaining sleeve abutsan end of the tubular base of the lower cam assembly. In an exemplaryembodiment, the tubular base of the lower cam assembly includes aplurality of circumferentially spaced apart meshing teeth for engagingthe meshing teeth of the float shoe adaptor. In an exemplary embodiment,the apparatus further includes a float shoe releasably coupled to thetorsional coupling of the float shoe adaptor, and an expandable tubularmember coupled to the float shoe and supported by and movably coupled tothe upper and lower expansion cone segments. In an exemplary embodiment,the apparatus further includes: one or more shear pins coupled betweenthe upper tubular support member and the lower tubular support member.In an exemplary embodiment, the apparatus further includes: a stopmember coupled to the upper tubular support member for limiting movementof the upper tubular support member relative to the lower tubularsupport member. In an exemplary embodiment, the apparatus furtherincludes: a float shoe releasably coupled to the lower tubular supportmember that defines a valveable passage, and an expandable tubularmember coupled to the float shoe and supported by and movably coupled tothe upper and lower expansion cone segments. In an exemplary embodiment,each upper expansion cone segment includes: an inner portion defining anarcuate cylindrical upper surface including a hinge groove for pivotallycoupling the upper expansion cone segment to the upper tubular supportmember and arcuate cylindrical lower surfaces, an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface, and an outer portion defining arcuate cylindricalupper and lower surfaces, and wherein each lower expansion cone segmentincludes: an inner portion defining an arcuate cylindrical upper surfaceincluding a hinge groove for pivotally coupling the lower expansion conesegment to the lower tubular support member and arcuate cylindricallower surfaces, an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface, and anouter portion defining arcuate cylindrical upper and lower surfaces. Inan exemplary embodiment, each upper expansion cone segment is tapered inthe longitudinal direction from the intermediate portion to the outerportion; and wherein each lower expansion cone segment is tapered in thelongitudinal direction from the intermediate portion to the outerportion.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has also been described that includes a safetycollar, a torque plate coupled to the safety collar including aplurality of circumferentially spaced apart meshing teeth at an end, anupper mandrel including a plurality of circumferentially spaced apartmeshing teeth at one end for engaging the meshing teeth of the torqueplate and an external flange at another end, a lower mandrel coupled tothe external flange of the upper mandrel including an external flangeincluding a plurality of circumferentially spaced apart meshing teeth, astop nut coupled to an end of the lower mandrel, an upper retainingsleeve coupled to the lower mandrel including an internal flange, one ormore cup seals coupled to the upper mandrel for sealing an interfacebetween the upper mandrel and the expandable tubular member, an uppercam assembly coupled to the lower mandrel including: a tubular baseincluding a plurality of circumferentially spaced apart meshing teethfor engaging the meshing teeth of the external flange of the lowermandrel, and a plurality of cam arms extending from the tubular base ina downward longitudinal direction, each cam arm defining an inclinedsurface, a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to theinternal flange of the upper retaining sleeve, a float shoe adapterincluding a plurality of circumferentially spaced apart meshing teeth atone end, an internal flange, and a torsional coupling at another end, alower retaining sleeve coupled to an end of the float shoe adapterincluding an internal flange, a retaining sleeve received within thefloat shoe adapter, one or more shear pins for releasably coupling theretaining sleeve to the stop nut, a lower cam assembly coupled to thefloat shoe adapter including: a tubular base including a plurality ofcircumferentially spaced apart meshing teeth for engaging the meshingteeth of the float shoe adapter, and a plurality of cam arms extendingfrom the tubular base in an upward longitudinal direction, each cam armdefining an inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments, wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly, a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the internal flange of thelower retaining sleeve and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly, a floatshoe releasably coupled to the torsional coupling of the float shoeadaptor, and an expandable tubular member coupled to the float shoe andsupported by and movably coupled to the upper and lower expansion conesegments, wherein the lower expansion cone segments interleave andoverlap the upper expansion cone segments, wherein the upper and lowerexpansion cone segments together define an arcuate spherical externalsurface for plastically deforming and radially expanding the expandabletubular member, wherein each upper expansion cone segment includes: aninner portion defining an arcuate cylindrical upper surface including ahinge groove for pivotally coupling the upper expansion cone segment tothe upper tubular support member and arcuate cylindrical lower surfaces,an intermediate portion defining arcuate cylindrical and spherical uppersurfaces and an arcuate conical lower surface, and an outer portiondefining arcuate cylindrical upper and lower surfaces, wherein eachlower expansion cone segment includes: an inner portion defining anarcuate cylindrical upper surface including a hinge groove for pivotallycoupling the lower expansion cone segment to the lower tubular supportmember and arcuate cylindrical lower surfaces, an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface, and an outer portion defining arcuate cylindricalupper and lower surfaces, wherein each upper expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion, and wherein each lower expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion.

A collapsible expansion cone assembly has also been described thatincludes an upper tubular support member including an internal flange,an upper cam assembly coupled to the upper tubular support memberincluding: a tubular base coupled to the upper support member, and aplurality of cam arms extending from the tubular base in a downwardlongitudinal direction, each cam arm defining an inclined surface, aplurality of upper expansion cone segments interleaved with the cam armsof the upper cam assembly and pivotally coupled to the internal flangeof the upper tubular support member, a lower tubular support memberincluding an internal flange, one or more frangible couplings forreleasably coupling the upper and lower tubular support members, a lowercam assembly coupled to the lower tubular support member including: atubular base coupled to the lower tubular support member, and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each cam arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion cone segments, wherein the cams arms of the upper cam assemblyare interleaved with and overlap the cam arms of the lower cam assembly,and a plurality of lower expansion cone segments interleaved with camarms of the lower cam assembly, each lower expansion cone segmentpivotally coupled to the internal flange of the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly, wherein the lower expansion conesegments interleave and overlap the upper expansion cone segments, andwherein the upper and lower expansion cone segments together define anarcuate spherical external surface for plastically deforming andradially expanding the expandable tubular member. In an exemplaryembodiment, each upper expansion cone segment includes: an inner portiondefining an arcuate cylindrical upper surface including a hinge groovefor pivotally coupling the upper expansion cone segment to the uppertubular support member and arcuate cylindrical lower surfaces, anintermediate portion defining arcuate cylindrical and spherical uppersurfaces and an arcuate conical lower surface, and an outer portiondefining arcuate cylindrical upper and lower surfaces, and wherein eachlower expansion cone segment includes: an inner portion defining anarcuate cylindrical upper surface including a hinge groove for pivotallycoupling the lower expansion cone segment to the lower tubular supportmember and arcuate cylindrical lower surfaces, an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface, and an outer portion defining arcuate cylindricalupper and lower surfaces. In an exemplary embodiment, each upperexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion, and wherein each lowerexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion.

A collapsible expansion cone assembly has also been described thatincludes an upper tubular support member including an internal flange,an upper cam assembly coupled to the upper tubular support memberincluding: a tubular base coupled to the upper support member, and aplurality of cam arms extending from the tubular base in a downwardlongitudinal direction, each cam arm defining an inclined surface, aplurality of upper expansion cone segments interleaved with the cam armsof the upper cam assembly and pivotally coupled to the internal flangeof the upper tubular support member, a lower tubular support memberincluding an internal flange, one or more frangible couplings forreleasably coupling the upper and lower tubular support members, a lowercam assembly coupled to the lower tubular support member including: atubular base coupled to the lower tubular support member, and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each cam arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion cone segments, wherein the cams arms of the upper cam assemblyare interleaved with and overlap the cam arms of the lower cam assembly,and a plurality of lower expansion cone segments interleaved with camarms of the lower cam assembly, each lower expansion cone segmentpivotally coupled to the internal flange of the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly, wherein the lower expansion conesegments interleave and overlap the upper expansion cone segments,wherein the upper and lower expansion cone segments together define anarcuate spherical external surface for plastically deforming andradially expanding the expandable tubular member, wherein each upperexpansion cone segment includes: an inner portion defining an arcuatecylindrical upper surface including a hinge groove for pivotallycoupling the upper expansion cone segment to the upper tubular supportmember and arcuate cylindrical lower surfaces, an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface, and an outer portion defining arcuate cylindricalupper and lower surfaces, wherein each lower expansion cone segmentincludes: an inner portion defining an arcuate cylindrical upper surfaceincluding a hinge groove for pivotally coupling the lower expansion conesegment to the lower tubular support member and arcuate cylindricallower surfaces, an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface, and anouter portion defining arcuate cylindrical upper and lower surfaces,wherein each upper expansion cone segment is tapered in the longitudinaldirection from the intermediate portion to the outer portion, andwherein each lower expansion cone segment is tapered in the longitudinaldirection from the intermediate portion to the outer portion.

An apparatus for radially expanding and plastically deforming anexpandable tubular member has also been described that includes atubular support member, a collapsible expansion cone coupled to thetubular support member, an expandable tubular member coupled to thecollapsible expansion cone, means for displacing the collapsibleexpansion cone relative to the expandable tubular member, and means forcollapsing the expansion cone. In an exemplary embodiment, the tubularsupport member includes an upper tubular support member including aninternal flange and a lower tubular support member including an internalflange, wherein the expansion cone includes: an upper cam assemblycoupled to the upper tubular support member including: a tubular basecoupled to the upper support member, and a plurality of cam armsextending from the tubular base in a downward longitudinal direction,each cam arm defining an inclined surface, a plurality of upperexpansion cone segments interleaved with the cam arms of the upper camassembly and pivotally coupled to the internal flange of the uppertubular support member, a lower cam assembly coupled to the lowertubular support member including: a tubular base coupled to the lowertubular support member, and a plurality of cam arms extending from thetubular base in an upward longitudinal direction, each cam arm definingan inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments, wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly, and a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the internal flange of thelower tubular support member and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly; and whereinthe apparatus further includes: means for releasably coupling the uppertubular support member to the lower tubular support member, and meansfor limiting movement of the upper tubular support member relative tothe lower tubular support member. In an exemplary embodiment, theapparatus further includes: means for pivoting the upper expansion conesegments, and means for pivoting the lower expansion cone segments. Inan exemplary embodiment, the apparatus further includes: means forpulling the collapsible expansion cone through the expandable tubularmember.

A collapsible expansion cone has also been described that includes anupper cam assembly including: a tubular base, and a plurality of camarms extending from the tubular base in a downward longitudinaldirection, each cam arm defining an inclined surface, a plurality ofupper expansion cone segments interleaved with the cam arms of the uppercam assembly, a lower cam assembly including: a tubular base, and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each cam arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion cone segments, wherein the cams arms of the upper cam assemblyare interleaved with and overlap the cam arms of the lower cam assembly,a plurality of lower expansion cone segments interleaved with cam armsof the lower cam assembly, each lower expansion cone segment mating withthe inclined surface of a corresponding one of the cam arms of the uppercam assembly, means for moving the upper cam assembly away from thelower expansion cone segments, and means for moving the lower camassembly away from the upper expansion cone segments. In an exemplaryembodiment, the upper and lower expansion cone segments together definean arcuate spherical external surface. In an exemplary embodiment, eachupper expansion cone segment includes: an inner portion defining anarcuate upper surface and arcuate cylindrical lower surfaces, anintermediate portion defining arcuate cylindrical and spherical uppersurfaces and an arcuate conical lower surface, and an outer portiondefining arcuate cylindrical upper and lower surfaces, and wherein eachlower expansion cone segment includes: an inner portion defining anarcuate cylindrical upper surface and arcuate cylindrical lowersurfaces, an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface, and anouter portion defining arcuate cylindrical upper and lower surfaces. Inan exemplary embodiment, each upper expansion cone segment is tapered inthe longitudinal direction from the intermediate portion to the outerportion, and each lower expansion cone segment is tapered in thelongitudinal direction from the intermediate portion to the outerportion.

A method of radially expanding and plastically deforming an expandabletubular member has also been described that includes supporting theexpandable tubular member using a tubular support member and acollapsible expansion cone, injecting a fluidic material into thetubular support member, sensing the operating pressure of the injectedfluidic material within a first interior portion of the tubular supportmember, displacing the collapsible expansion cone relative to theexpandable tubular member when the sensed operating pressure of theinjected fluidic material exceeds a predetermined level within the firstinterior portion of the tubular support member, sensing the operatingpressure of the injected fluidic material within a second interiorportion of the tubular support member, and collapsing the collapsibleexpansion cone when the sensed operating pressure of the injectedfluidic material exceeds a predetermined level within the secondinterior portion of the tubular support member. In an exemplaryembodiment, the method further includes: pulling the collapsibleexpansion cone through the expandable tubular member when the sensedoperating pressure of the injected fluidic material exceeds apredetermined level within the first interior portion of the tubularsupport member. In an exemplary embodiment, pulling the collapsibleexpansion cone through the expandable tubular member includes: couplingone or more cup seals to the tubular support member above thecollapsible expansion cone, pressuring the interior of the expandabletubular member below the cup seals, and pulling the collapsibleexpansion cone through the expandable tubular member using the cupseals. In an exemplary embodiment, the tubular support member includesan upper tubular support member and a lower tubular support member, andwherein collapsing the collapsible expansion cone includes displacingthe upper tubular member relative to the lower tubular support member.In an exemplary embodiment, the collapsible expansion cone includes: anupper cam assembly including: a tubular base, and a plurality of camarms extending from the tubular base in a downward longitudinaldirection, each cam arm defining an inclined surface, a plurality ofupper expansion cone segments interleaved with the cam arms of the uppercam assembly and pivotally coupled to the upper tubular support member,a lower cam assembly including: a tubular base, and a plurality of camarms extending from the tubular base in an upward longitudinaldirection, each cam arm defining an inclined surface that mates with theinclined surface of a corresponding one of the upper expansion conesegments, wherein the cams arms of the upper cam assembly areinterleaved with and overlap the cam arms of the lower cam assembly, anda plurality of lower expansion cone segments interleaved with cam armsof the lower cam assembly, each lower expansion cone segment pivotallycoupled to the lower tubular support member and mating with the inclinedsurface of a corresponding one of the cam arms of the upper camassembly.

It is understood that variations may be made in the foregoing withoutdeparting from the scope of the invention. For example, the teachings ofthe present illustrative embodiments may be used to provide a wellborecasing, a pipeline, or a structural support. Furthermore, the elementsand teachings of the various illustrative embodiments may be combined inwhole or in part in some or all of the illustrative embodiments. Inaddition, the expansion surfaces of the expansion cone segments mayinclude any form of inclined surface or combination of inclined surfacesuch as, for example, conical, spherical, elliptical, and/or parabolic.

Although illustrative embodiments of the invention have been shown anddescribed, a wide range of modification, changes and substitution iscontemplated in the foregoing disclosure. In some instances, somefeatures of the present invention may be employed without acorresponding use of the other features. Accordingly, it is appropriatethat the appended claims be construed broadly and in a manner consistentwith the scope of the invention.

1. An apparatus for radially expanding and plastically deforming anexpandable tubular member, comprising: an upper tubular support memberdefining a first passage; one or more cup seals coupled to the exteriorsurface of the upper tubular support member for sealing an interfacebetween the upper tubular support member and the expandable tubularmember; an upper cam assembly coupled to the upper tubular supportmember comprising: a tubular base coupled to the upper tubular supportmember; and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to thetubular support member; a lower tubular support member defining a secondpassage fluidicly coupled to the first passage releasably coupled to theupper tubular support member; a lower cam assembly coupled to the lowertubular support member comprising: a tubular base coupled to the lowertubular support member; and a plurality of cam arms extending from thetubular base in an upward longitudinal direction, each cam arm definingan inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments; wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly; and a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly; wherein the lower expansion conesegments interleave and overlap the upper expansion cone segments; andwherein the upper and lower expansion cone segments together define anarcuate spherical external surface for plastically deforming andradially expanding the expandable tubular member.
 2. The apparatus ofclaim 1, wherein the upper tubular support member comprises: a safetycollar; a torque plate coupled to the safety collar comprising aplurality of circumferentially spaced apart meshing teeth at an end; anupper mandrel comprising a plurality of circumferentially spaced apartmeshing teeth at one end for engaging the meshing teeth of the torqueplate and an external flange at another end; and a lower mandrel coupledto the external flange of the upper mandrel comprising an externalflange comprising a plurality of circumferentially spaced apart meshingteeth.
 3. The apparatus of claim 2, wherein the tubular base of theupper cam assembly comprises a plurality of circumferentially spacedapart meshing teeth for engaging the meshing teeth of the externalflange of the lower mandrel.
 4. The apparatus of claim 2, furthercomprising: a stop nut coupled to an end of the lower mandrel forlimiting the movement of the lower tubular member relative to the lowermandrel.
 5. The apparatus of claim 2, further comprising: locking dogscoupled to the lower mandrel.
 6. The apparatus of claim 1, wherein thelower tubular support member comprises: a float shoe adapter comprisinga plurality of circumferentially spaced apart meshing teeth at one end,an internal flange, and a torsional coupling at another end; a lowerretaining sleeve coupled to an end of the float shoe adapter comprisingan internal flange for pivotally engaging the lower expansion conesegments; and a retaining sleeve received within the float shoe adapterreleasably coupled to the tipper tubular support member.
 7. Theapparatus of claim 6, wherein an end of the retaining sleeve abuts anend of the tubular base of the lower cam assembly.
 8. The apparatus ofclaim 6, wherein the tubular base of the lower cam assembly comprises aplurality of circumferentially spaced apart meshing teeth for engagingthe meshing teeth of the float shoe adaptor.
 9. The apparatus of claim6, further comprising: a float shoe releasably coupled to the torsionalcoupling of the float shoe adaptor; and an expandable tubular membercoupled to the float shoe and supported by and movably coupled to theupper and lower expansion cone segments.
 10. The apparatus of claim 1,further comprising: one or more shear pins coupled between the uppertubular support member and the lower tubular support member.
 11. Theapparatus of claim 1, further comprising: a stop member coupled to theupper tubular support member for limiting movement of the upper tubularsupport member relative to the lower tubular support member.
 12. Theapparatus of claim 1, further comprising: a float shoe releasablycoupled to the lower tubular support member that defines a valveablepassage; and an expandable tubular member coupled to the float shoe andsupported by and movably coupled to the upper and lower expansion conesegments.
 13. The apparatus of claim 1, wherein each upper expansioncone segment comprises: an inner portion defining an arcuate cylindricalupper surface including a hinge groove for pivotally coupling the upperexpansion cone segment to the upper tubular support member and arcuatecylindrical lower surfaces; an intermediate portion defining arcuatecylindrical and spherical upper surfaces and an arcuate conical lowersurface; and an outer portion defining arcuate cylindrical upper andlower surfaces; and wherein each lower expansion cone segment comprises:an inner portion defining an arcuate cylindrical upper surface includinga hinge groove for pivotally coupling the lower expansion cone segmentto the lower tubular support member and arcuate cylindrical lowersurfaces; an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface; and anouter portion defining arcuate cylindrical upper and lower surfaces. 14.The apparatus of claim 13, wherein each upper expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion; and wherein each lower expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion.
 15. An apparatus for radially expanding andplastically deforming an expandable tubular member, comprising: a safetycollar; a torque plate coupled to the safety collar comprising aplurality of circumferentially spaced apart meshing teeth at an end; anupper mandrel comprising a plurality of circumferentially spaced apartmeshing teeth at one end for engaging the meshing teeth of the torqueplate and an external flange at another end; a lower mandrel coupled tothe external flange of the upper mandrel comprising an external flangecomprising a plurality of circumferentially spaced apart meshing teeth;a stop nut coupled to an end of the lower mandrel; an upper retainingsleeve coupled to the lower mandrel comprising an internal flange; oneor more cup seals coupled to the upper mandrel for sealing an interfacebetween the upper mandrel and the expandable tubular member; an uppercam assembly coupled to the lower mandrel comprising: a tubular basecomprising a plurality of circumferentially spaced apart meshing teethfor engaging the meshing teeth of the external flange of the lowermandrel; and a plurality of cam arms extending from the tubular base ina downward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved witthe cam arms of the upper cam assembly and pivotally coupled to theinternal flange of the upper retaining sleeve; a float shoe adaptercomprising a plurality of circumferentially spaced apart meshing teethat one end, an internal flange, and a torsional coupling at another end;a lower retaining sleeve coupled to an end of the float shoe adaptercomprising an internal flange; a retaining sleeve received within thefloat shoe adapter; one or more shear pins for releasably coupling theretaining sleeve to the stop nut; a lower cam assembly coupled to thefloat shoe adapter comprising: a tubular base comprising a plurality ofcircumferentially spaced apart meshing teeth for engaging the meshingteeth of the float shoe adapter; and a plurality of cam arms extendingfrom the tubular base in an upward longitudinal direction, each cam armdefining an inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments; wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly; a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the internal flange of thelower retaining sleeve and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly; a floatshoe releasably coupled to the torsional coupling of the float shoeadaptor; and an expandable tubular member coupled to the float shoe andsupported by and movably coupled to the upper and lower expansion conesegments; wherein the lower expansion cone segments interleave andoverlap the upper expansion cone segments; wherein the upper and lowerexpansion cone segments together define an arcuate spherical externalsurface for plastically deforming and radially expanding the expandabletubular member; wherein each upper expansion cone segment comprises: aninner portion defining an arcuate cylindrical upper surface including ahinge groove for pivotally coupling the upper expansion cone segment tothe upper tubular support member and arcuate cylindrical lower surfaces;an intermediate portion defining arcuate cylindrical and spherical uppersurfaces and an arcuate conical lower surface; and an outer portiondefining arcuate cylindrical upper and lower surfaces; wherein eachlower expansion cone segment comprises: an inner portion defining anarcuate cylindrical upper surface including a hinge groove for pivotallycoupling the lower expansion cone segment to the lower tubular supportmember and arcuate cylindrical lower surfaces; an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface; and an outer portion defining arcuate cylindricalupper and lower surfaces; wherein each upper expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion; and wherein each lower expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion.
 16. A collapsible expansion cone assembly comprising:an upper tubular support member comprising an internal flange; an uppercam assembly coupled to the upper tubular support member comprising: atubular base coupled to the upper support member; and a plurality of camarms extending from the tubular base in a downward longitudinaldirection, each cam arm defining an inclined surface; a plurality ofupper expansion cone segments interleaved with the cam arms of the uppercam assembly and pivotally coupled to the internal flange of the uppertubular support member; a lower tubular support member comprising aninternal flange; one or more frangible couplings for releasably couplingthe upper and lower tubular support members; a lower cam assemblycoupled to the lower tubular support member comprising: a tubular basecoupled to the lower tubular support member; and a plurality of cam armsextending from the tubular base in an upward longitudinal direction,each cam arm defining an inclined surface that mates with the inclinedsurface of a corresponding one of the upper expansion cone segments;wherein the cams arms of the upper cam assembly are interleaved with andoverlap the cam arms of the lower cam assembly; and a plurality of lowerexpansion cone segments interleaved with cam arms of the lower camassembly, each lower expansion cone segment pivotally coupled to theinternal flange of the lower tubular support member and mating with theinclined surface of a corresponding one of the cam arms of the upper camassembly; wherein the lower expansion cone segments interleave andoverlap the upper expansion cone segments; and wherein the upper andlower expansion cone segments together define an arcuate sphericalexternal surface for plastically deforming and radially expanding theexpandable tubular member.
 17. The assembly of claim 16, wherein eachupper expansion cone segment comprises: an inner portion defining anarcuate cylindrical upper surface including a hinge groove for pivotallycoupling the upper expansion cone segment to the upper tubular supportmember and arcuate cylindrical lower surfaces; an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface; and an outer portion defining arcuate cylindricalupper and lower surfaces; and wherein each lower expansion cone segmentcomprises: an inner portion defining an arcuate cylindrical uppersurface including a hinge groove for pivotally coupling the lowerexpansion cone segment to the lower tubular support member and arcuatecylindrical lower surfaces; an intermediate portion defining arcuatecylindrical and spherical upper surfaces and an arcuate conical lowersurface; and an outer portion defining arcuate cylindrical upper andlower surfaces.
 18. The assembly of claim 16, wherein each upperexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion; and wherein each lowerexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion.
 19. A collapsible expansioncone assembly, comprising: upper tubular support member comprising aninternal flange; an upper earn assembly coupled to the upper tubularsupport member comprising: a tubular base coupled to the upper supportmember; and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to theinternal flange of the upper tubular support member; a lower tubularsupport member comprising an internal flange; one or more frangiblecouplings for releasably coupling the upper and lower tubular supportmembers; a lower cam assembly coupled to the lower tubular supportmember comprising: a tubular base coupled to the lower tubular supportmember; and a plurality of cam arms extending from the tubular base inan upward longitudinal direction, each cam arm defining an inclinedsurface that mates with the inclined surface of a corresponding one ofthe upper expansion cone segments; wherein the cams arms of the uppercam assembly are interleaved with and overlap the cam arms of the lowercam assembly; and a plurality of lower expansion cone segmentsinterleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the internal flange of thelower tubular support member and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly; wherein thelower expansion cone segments interleave and overlap the upper expansioncone segments; wherein the upper and lower expansion cone segmentstogether define an arcuate spherical external surface for plasticallydeforming and radially expanding the expandable tubular member; whereineach upper expansion cone segment comprises: an inner portion definingan arcuate cylindrical upper surface including a hinge groove forpivotally coupling the upper expansion cone segment to the upper tubularsupport member and arcuate cylindrical lower surfaces; an intermediateportion defining arcuate cylindrical and spherical upper surfaces and anarcuate conical lower surface; and an outer portion defining arcuatecylindrical upper and lower surfaces; wherein each lower expansion conesegment comprises: an inner portion defining an arcuate cylindricalupper surface including a binge groove for pivotally coupling the lowerexpansion cone segment to the lower tabular support member and arcuatecylindrical lower surfaces; an intermediate portion defining arcuatecylindrical and spherical upper surfaces and an arcuate conical lowersurface; and an outer portion defining arcuate cylindrical upper andlower surfaces; wherein each upper expansion cone segment is tapered inthe longitudinal direction from the intermediate portion to the outerportion; and wherein each lower expansion cone segment is tapered in thelongitudinal direction from the intermediate portion to the outerportion.
 20. An apparatus for radially expanding and plasticallydeforming an expandable tubular member, comprising: a tubular supportmember; a collapsible expansion cone coupled to the tubular supportmember; an expandable tubular member coupled to the collapsibleexpansion cone; means for displacing the collapsible expansion conerelative to the expandable tubular member; and means for collapsing theexpansion cone; wherein the tubular support member comprises an uppertubular support member comprising an internal flange and a lower tubularsupport member comprising an internal flange; wherein the expansion conecomprises: an upper cam assembly coupled to the upper tubular supportmember comprising: a tubular base coupled to the upper support member;and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to theinternal flange of the upper tubular support member; a lower camassembly coupled to the lower tubular support member comprising: atubular base coupled to the lower tubular support member; and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each earn arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion cone segments; wherein the cams arms of the upper cam assemblyare interleaved with and overlap the cam arms of the lower cam assembly;and a plurality of lower expansion cone segments interleaved with camarms of the lower cam assembly, each lower expansion cone segmentpivotally coupled to the internal flange of the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly; and wherein the apparatusfurther comprises: means for releasably coupling the upper tubularsupport member to the lower tubular support member; and means forlimiting movement of the upper tubular support member relative to thelower tubular support member.
 21. The apparatus of claim 20, furthercomprising: means for pivoting the upper expansion cone segments; andmeans for pivoting the lower expansion cone segments.
 22. A collapsibleexpansion cone, comprising: an upper cam assembly comprising: a tubularbase; and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly; a lower cam assembly comprising:a tubular base; and a plurality of cam arms extending from the tubularbase in an upward longitudinal direction, each cam arm defining aninclined surface that mates with the inclined surface of a correspondingone of the upper expansion cone segments; wherein the cams arms of theupper cam assembly are interleaved with and overlap the cam arms of thelower cam assembly; a plurality of lower expansion cone segmentsinterleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly; means formoving the upper cam assembly away from the lower expansion conesegments; and means for moving the lower cam assembly away from theupper expansion cone segments.
 23. The apparatus of claim 22, whereinthe upper and lower expansion cone segments together define an arcuatespherical external surface.
 24. The apparatus of claim 22, wherein eachupper expansion cone segment comprises: an inner portion defining anarcuate cylindrical upper surface and arcuate cylindrical lowersurfaces; an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface; and anouter portion defining arcuate cylindrical upper and lower surfaces; andwherein each lower expansion cone segment comprises: an inner portiondefining an arcuate cylindrical upper surface and arcuate cylindricallower surfaces; an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface; and anouter portion defining arcuate cylindrical upper and lower surfaces. 25.The apparatus of claim 22, wherein each upper expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion; and wherein each lower expansion cone segment istapered in the longitudinal direction from the intermediate portion tothe outer portion.
 26. A method of radially expanding and plasticallydeforming an expandable tubular member, comprising: supporting theexpandable tubular member using a tubular support member and acollapsible expansion cone; injecting a fluidic material into thetubular support member; sensing the operating pressure of the ininjected fluidic material within a first interior portion of the tubularsupport member; displacing the collapsible expansion cone relative tothe expandable tubular member when the sensed operating pressure of theinjected fluidic material exceeds a predetermined level within the firstinterior portion of the tubular support member; sensing the operatingpressure of the injected fluidic material within a second interiorportion of the tubular support member; and collapsing the collapsibleexpansion cone when the sensed operating pressure of the injectedfluidic material exceeds a predetermined level within the secondinterior portion of the tubular support member.
 27. The method of claim26, further comprising: pulling the collapsible expansion cone throughthe expandable tubular member when the sensed operating pressure of theinjected fluidic material exceeds a predetermined level within the firstinterior portion of the tubular support member.
 28. The method of claim27, wherein pulling the collapsible expansion cone through theexpandable tubular member comprises: coupling one or more cup seals tothe tubular support member above the collapsible expansion cone;pressuring the interior of the expandable tubular member below the cupseals; and pulling the collapsible expansion cone through the expandabletubular member using the cup seals.
 29. The method of claim 26, whereinthe tubular support member comprises an upper tubular support member anda lower tubular support member; and wherein collapsing the collapsibleexpansion cone comprises displacing the upper tubular member relative tothe lower tubular support member.
 30. The method of claim 29, whereinthe collapsible expansion cone comprises: an upper cam assemblycomprising: a tubular base; and a plurality of cam arms extending fromthe tubular base in a downward longitudinal direction, each cam armdefining an inclined surface; a plurality of upper expansion conesegments interleaved with the cam arms of the upper cam assembly andpivotally coupled to the upper tubular support member; a lower camassembly comprising: a tubular base; and a plurality of cam armsextending from the tubular base in an upward longitudinal direction,each cam arm defining an inclined surface that mates with the inclinedsurface of a corresponding one of the upper expansion cone segments;wherein the cams arms of the upper cam assembly are interleaved with andoverlap the cam arms of the lower cam assembly; and a plurality of lowerexpansion cone segments interleaved with cam arms of the lower camassembly, each lower expansion cone segment pivotally coupled to thelower tubular support member and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly.
 31. Anapparatus for radially expanding and plastically deforming an expandabletubular member, comprising: an upper tubular support member defining afirst passage; one or more cup seals coupled to the exterior surface ofthe upper tubular support member for sealing an interface between theupper tubular support member and the expandable tubular member; and anadjustable expansion device coupled to the upper tubular support memberadapted to be controllably adjusted between a smaller outside diameterand a larger outside diameter; wherein the adjustable expansion devicecomprises: an upper cam assembly coupled to the upper tubular supportmember comprising: a tubular base coupled to the upper tubular supportmember; and a plurality of cam arms extending from the tubular base in adownward longitudinal direction, each cam arm defining an inclinedsurface; a plurality of upper expansion cone segments interleaved withthe cam arms of the upper cam assembly and pivotally coupled to theupper tubular support member; a lower tubular support member defining asecond passage fluidicly coupled to the first passage releasably coupledto the upper tubular support member; a lower cam assembly coupled to thelower tubular support member comprising: a tubular base coupled to thelower tubular support member; and a plurality of cam arms extending fromthe tubular base in an upward longitudinal direction, each cam armdefining an inclined surface that mates with the inclined surface of acorresponding one of the upper expansion cone segments; wherein the camsarms of the upper cam assembly are interleaved with and overlap the camarms of the lower cam assembly; and a plurality of lower expansion conesegments interleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the lower tubular supportmember and mating with the inclined surface of a corresponding one ofthe cam arms of the upper cam assembly.
 32. The apparatus of claim 31,wherein the lower expansion cone segments interleave and overlap theupper expansion cone segments; and wherein the upper and lower expansioncone segments together define an arcuate spherical external surface forplastically deforming and radially expanding the expandable tubularmember.
 33. A collapsible expansion cone assembly comprising: an uppertubular support member comprising an internal flange; an upper earnassembly coupled to the upper tubular support member comprising: atubular base coupled to the upper support member; and a plurality of camarms extending from the tubular base in a downward longitudinaldirection, each cam arm defining an inclined surface; a plurality ofupper expansion cone segments interleaved with the cam arms of the uppercam assembly and pivotally coupled to the internal flange of the uppertubular support member; a lower tubular support member comprising aninternal flange; a lower cam assembly coupled to the lower tubularsupport member comprising: a tubular base coupled to the lower tabularsupport member; and a plurality of cam arms extending from the tubularbase in an upward longitudinal direction, each cam arm defining aninclined surface that mates with the inclined surface of a correspondingone of the upper expansion cone segments; wherein the cams arms of theupper cam assembly are interleaved with and overlap the cam arms of thelower cam assembly; and a plurality of lower expansion cone segmentsinterleaved with cam arms of the lower cam assembly, each lowerexpansion cone segment pivotally coupled to the internal flange of thelower tubular support member and mating with the inclined surface of acorresponding one of the cam arms of the upper cam assembly; wherein thelower expansion cone segments interleave and overlap the upper expansioncone segments.
 34. The assembly of claim 33, wherein the upper and lowerexpansion cone segments together define an arcuate spherical externalsurface for plastically deforming and radially expanding the expandabletubular member.
 35. The assembly of claim 33, wherein each upperexpansion cone segment comprises: an inner portion defining an arcuatecylindrical upper surface including a hinge groove for pivotallycoupling the upper expansion cone segment to the upper tubular supportmember and arcuate cylindrical lower surfaces; an intermediate portiondefining arcuate cylindrical and spherical upper surfaces and an arcuateconical lower surface; and an outer portion defining arcuate cylindricalupper and lower surfaces; and wherein each lower expansion cone segmentcomprises: an inner portion defining an arcuate cylindrical uppersurface including a hinge groove for pivotally coupling the lowerexpansion cone segment to the lower tubular support member and arcuatecylindrical lower surfaces; an intermediate portion defining arcuatecylindrical and spherical upper surfaces and an arcuate conical lowersurface; and an outer portion defining arcuate cylindrical upper andlower surfaces.
 36. The assembly of claim 33, wherein each upperexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion; and wherein each lowerexpansion cone segment is tapered in the longitudinal direction from theintermediate portion to the outer portion.
 37. A method of radiallyexpanding and plastically deforming an expandable tubular member,comprising: supporting the expandable tubular member using a tubularsupport member and an adjustable expansion device; injecting a fluidicmaterial into the tubular support member; sensing the operating pressureof the injected fluidic material within a first interior portion of thetubular support member; displacing the adjustable expansion devicerelative to the expandable tubular member when the sensed operatingpressure of the injected fluidic material exceeds a predetermined levelwithin the first interior portion of the tubular support member; sensingthe operating pressure of the injected fluidic material within a secondinterior portion of the tubular support member; and reducing the outsidediameter of the adjustable expansion device when the sensed operatingpressure of the injected fluidic material exceeds a predetermined levelwithin the second interior portion of the tubular support member. 38.The method of claim 37, further comprising: pulling the adjustableexpansion device through the expandable tubular member when the sensedoperating pressure of the injected fluidic material exceeds apredetermined level within the first interior portion of the tubularsupport member.
 39. The method of claim 38, wherein pulling theadjustable expansion device though the expandable tubular membercomprises: coupling one or more cup seals to the tubular support memberabove the adjustable expansion device; pressuring the interior of theexpandable tubular member below the cup seals; and pulling theadjustable expansion device though the expandable tubular member usingthe cup seals.
 40. A system for radially expanding and plasticallydeforming an expandable tubular member, comprising: means for supportingthe expandable tubular member using a tubular support member and anadjustable expansion device; means for injecting a fluidic material intothe tubular support member; means for sensing the operating pressure ofthe injected fluidic material within a first interior portion of thetubular support member; means for displacing the adjustable expansiondevice relative to the expandable tubular member when the sensedoperating pressure of the injected fluidic material exceeds apredetermined level within the first interior portion of the tubularsupport member; means for sensing the operating pressure of the injectedfluidic material within a second interior portion of the tubular supportmember; and means for reducing the outside diameter of the adjustableexpansion device when the sensed operating pressure of the injectedfluidic material exceeds a predetermined level within the secondinterior portion of the tubular support member.
 41. The system of claim40, further comprising: means for pulling the adjustable expansiondevice through the expandable tubular member when the sensed operatingpressure of the injected fluidic material exceeds a predetermined levelwithin the first interior portion of the tubular support member.
 42. Thesystem of claim 41, wherein means for pulling the adjustable expansiondevice through the expandable tubular member comprises: means forcoupling one or more cup seals to the tubular support member above theadjustable expansion device; means for pressuring the interior of theexpandable tubular member below the cup seals; and means for pulling theadjustable expansion device through the expandable tubular member usingthe cup seals.
 43. A collapsible expansion device, comprising: an uppercam assembly comprising: a tubular base; and a plurality of cam armsextending from the tubular base in a downward longitudinal direction,each cam arm defining an inclined surface; a plurality of upperexpansion segments interleaved with the cam arms of the upper camassembly; a lower cam assembly comprising: a tubular base; and aplurality of cam arms extending from the tubular base in an upwardlongitudinal direction, each cam arm defining an inclined surface thatmates with the inclined surface of a corresponding one of the upperexpansion segments; wherein the cams arms of the upper cam assembly areinterleaved with and overlap the cam arms of the lower cam assembly; aplurality of lower expansion segments interleaved with cam arms of thelower cam assembly, each lower expansion segment mating with theinclined surface of a corresponding one of the cam arms of the upper camassembly; means for moving the upper cam assembly away from the lowerexpansion segments; and means for moving the lower cam assembly awayfrom the upper expansion segments.
 44. The apparatus of claim 43,wherein the upper and lower expansion segments together define anarcuate spherical external surface.
 45. The apparatus of claim 43,wherein each upper expansion segment comprises: an inner portiondefining an arcuate cylindrical upper surface and arcuate cylindricallower surfaces; an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface; and anouter portion defining arcuate cylindrical upper and lower surfaces; andwherein each lower expansion segment comprises: an inner portiondefining an arcuate cylindrical upper surface and arcuate cylindricallower surfaces; an intermediate portion defining arcuate cylindrical andspherical upper surfaces and an arcuate conical lower surface; and anouter portion defining arcuate cylindrical upper and lower surfaces. 46.The apparatus of claim 43, wherein each upper expansion segment istapered in the longitudinal direction from the intermediate portion tothe outer portion; and wherein each lower expansion segment is taperedin the longitudinal direction from the intermediate portion to the outerportion.